Printed by Kawasaki under document number 93209-00240, this 264-page shop manual is the factory book for the 80ZV wheel loader, now supplied as a Kawasaki 80ZV shop manual PDF. The torque converter and transmission group takes up a large share of the pages and takes both assemblies through complete teardown and reassembly. The hydraulic group covers pump removal and the boom, bucket and steering cylinders. Chassis, power, brake and operator station groups follow the same pattern: removal and reinstallation, disassembly, then a service standard listing the limits you measure against. Set the parking brake actuator clearance at 1 mm (0.04 in.), and expect the hydraulic pump to deliver 64.5 cm3/rev at up to 2,400 rpm when you check its output. A parked loader burns hours you never get back. Your copy is bookmarked by group and text-searchable, downloads straight away and helps put the 80ZV back on the pile.
What's Inside This Manual
| System | Pages | Key Topics |
|---|
| Chassis Group | 17-44 | Removing and Reinstalling Deck, Removing and Reinstalling Fuel Tank, Removing and Reinstalling Hydraulic Tank, Removing and Reinstalling Engine Room, Removing and Reinstalling Cab |
| Power Group | 45-104 | Removing and Reinstalling Radiator, Removing and Reinstalling Engine, Removing and Reinstalling Propeller Shaft, Removing and Reinstalling Air Cleaner |
| Torque Converter & Transmission Group | 105-160 | Removing and Reinstalling Torque Converter and Transmission Assembly, Disassembling and Reassembling Torque Converter Assembly, Disassembling and Reassembling Transmission Assembly |
| Hydraulic Group | 161-220 | Removing and Reinstalling Hydraulic Pump Assembly, Removing and Reinstalling Boom Cylinder, Removing and Reinstalling Bucket Cylinder, Removing and Reinstalling Steering Cylinder |
| Brake Group | 221-252 | Removing and Reinstalling Unloader Valve, Removing and Reinstalling Valve Assembly, Removing and Reinstalling Accumulator, Removing and Reinstalling Brake Valve |
| Operator Station Group | 253-264 | Disassembly & Reassembly, Service Standard |
Quick Reference Specifications
| Specification | Value | Page |
|---|
| Retainer bolt (16) | 230 N-m (23.5 kgf-m) (170 lb-ft) | p. 19 |
| Hydraulic pump theoretical discharge | 64.5 cm3/rev (3.9 in3/rev) | p. 157 |
| Parking brake actuator clearance | 1mm (0.04in.) | p. 33 |
| Solenoid valve nut tightening torque | 10 N-m (1.0 kgf-m) (7 lb-ft) | p. 178 |
| Hydraulic pump maximum operation speed | 2,400 min-1 (rpm) | p. 157 |
| Bolt (bracket) | 73.5 N-m (7.5 kgf-m) (54 lb-ft) | p. 237 |
| Lock nut (stopper bolt) | 9.8 N-m (1.0 kgf-m) (7.2 lb-ft) | p. 237 |
| Retainer bolts (park brake actuator) | 53 N-m (5.4 kgf-m) (39 lb-ft) | p. 239 |
| Head bolt of magnetic clutch | 18 N-m (1.8 kgf-m) | p. 260 |
| Air compressor (with magnetic clutch) T2 | 18 N-m (1.8 kgf-m) | p. 260 |
| Fuel Tank Capacity | 271 L | p. 19 |
| Transmission Oil Capacity | 35 L | p. 107 |
